US20040102380A1 - Method for continuous, automated blending of solutions from acids and bases - Google Patents

Method for continuous, automated blending of solutions from acids and bases Download PDF

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US20040102380A1
US20040102380A1 US10/715,701 US71570103A US2004102380A1 US 20040102380 A1 US20040102380 A1 US 20040102380A1 US 71570103 A US71570103 A US 71570103A US 2004102380 A1 US2004102380 A1 US 2004102380A1
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solutions
blending
solution
continuous
bases
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Scott Fulton
Peter Brown
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TAURUS HSA LLC
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    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07K—PEPTIDES
    • C07K14/00—Peptides having more than 20 amino acids; Gastrins; Somatostatins; Melanotropins; Derivatives thereof
    • C07K14/435—Peptides having more than 20 amino acids; Gastrins; Somatostatins; Melanotropins; Derivatives thereof from animals; from humans
    • C07K14/76—Albumins
    • C07K14/765—Serum albumin, e.g. HSA
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K47/00—Medicinal preparations characterised by the non-active ingredients used, e.g. carriers or inert additives; Targeting or modifying agents chemically bound to the active ingredient
    • A61K47/02—Inorganic compounds
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K47/00—Medicinal preparations characterised by the non-active ingredients used, e.g. carriers or inert additives; Targeting or modifying agents chemically bound to the active ingredient
    • A61K47/06—Organic compounds, e.g. natural or synthetic hydrocarbons, polyolefins, mineral oil, petrolatum or ozokerite
    • A61K47/08—Organic compounds, e.g. natural or synthetic hydrocarbons, polyolefins, mineral oil, petrolatum or ozokerite containing oxygen, e.g. ethers, acetals, ketones, quinones, aldehydes, peroxides
    • A61K47/12—Carboxylic acids; Salts or anhydrides thereof
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61P—SPECIFIC THERAPEUTIC ACTIVITY OF CHEMICAL COMPOUNDS OR MEDICINAL PREPARATIONS
    • A61P1/00—Drugs for disorders of the alimentary tract or the digestive system
    • A61P1/16—Drugs for disorders of the alimentary tract or the digestive system for liver or gallbladder disorders, e.g. hepatoprotective agents, cholagogues, litholytics
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61P—SPECIFIC THERAPEUTIC ACTIVITY OF CHEMICAL COMPOUNDS OR MEDICINAL PREPARATIONS
    • A61P1/00—Drugs for disorders of the alimentary tract or the digestive system
    • A61P1/18—Drugs for disorders of the alimentary tract or the digestive system for pancreatic disorders, e.g. pancreatic enzymes
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61P—SPECIFIC THERAPEUTIC ACTIVITY OF CHEMICAL COMPOUNDS OR MEDICINAL PREPARATIONS
    • A61P13/00—Drugs for disorders of the urinary system
    • A61P13/12—Drugs for disorders of the urinary system of the kidneys
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61P—SPECIFIC THERAPEUTIC ACTIVITY OF CHEMICAL COMPOUNDS OR MEDICINAL PREPARATIONS
    • A61P17/00—Drugs for dermatological disorders
    • A61P17/02—Drugs for dermatological disorders for treating wounds, ulcers, burns, scars, keloids, or the like
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61P—SPECIFIC THERAPEUTIC ACTIVITY OF CHEMICAL COMPOUNDS OR MEDICINAL PREPARATIONS
    • A61P3/00—Drugs for disorders of the metabolism
    • A61P3/08—Drugs for disorders of the metabolism for glucose homeostasis
    • A61P3/10—Drugs for disorders of the metabolism for glucose homeostasis for hyperglycaemia, e.g. antidiabetics
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61P—SPECIFIC THERAPEUTIC ACTIVITY OF CHEMICAL COMPOUNDS OR MEDICINAL PREPARATIONS
    • A61P7/00—Drugs for disorders of the blood or the extracellular fluid
    • A61P7/10—Antioedematous agents; Diuretics
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07K—PEPTIDES
    • C07K14/00—Peptides having more than 20 amino acids; Gastrins; Somatostatins; Melanotropins; Derivatives thereof
    • C07K14/435—Peptides having more than 20 amino acids; Gastrins; Somatostatins; Melanotropins; Derivatives thereof from animals; from humans
    • C07K14/46—Peptides having more than 20 amino acids; Gastrins; Somatostatins; Melanotropins; Derivatives thereof from animals; from humans from vertebrates
    • C07K14/47—Peptides having more than 20 amino acids; Gastrins; Somatostatins; Melanotropins; Derivatives thereof from animals; from humans from vertebrates from mammals
    • C07K14/4701—Peptides having more than 20 amino acids; Gastrins; Somatostatins; Melanotropins; Derivatives thereof from animals; from humans from vertebrates from mammals not used
    • C07K14/4715—Pregnancy proteins, e.g. placenta proteins, alpha-feto-protein, pregnancy specific beta glycoprotein

Definitions

  • the present invention relates to an improved and more efficient method of producing aqueous buffers and other aqueous solutions used for various unit operations such as chromatography in the processing of biopharmaceuticals or other applications by utilizing continuous generation from common stocks of concentrated constitutive acids and bases, as well as salts and other needed reagents.
  • the present invention is directed to a method of producing solutions which require pH-controlled buffers either for product processing operations or as the final product.
  • These processes or products have in common the need to control pH, which is done through the use of a buffer compound containing ionizable groups, and adjusting the pH of the solution to within approximately 1 pH unit above or below the pKa of the ionizable groups.
  • the ionization equilibrium of the ionizing groups has a buffering effect, making the pH of the solution reasonably stable to small changes in pH from chemical reactions to which it may be exposed that add or remove hydrogen ions from the solution.
  • these pH buffer solutions are usually created by making an aqueous solution of a purified salt form of the buffering compound, adding any additional solution components required for the application (such as other salts, surfactants microbial inhibitors, and the like) and then adjusting the pH of the solution up or down by the controlled addition of either acid or base (often HCl or NaOH) as required.
  • the buffering compound and additives are most often in the form of dried (often crystalline) salts, which are relatively expensive.
  • the acid or base forms of the buffering compound are often supplied as a concentrated liquid, and are most often substantially less expensive than the corresponding dried salt.
  • pH buffered solutions include all of the unit operations used in production and downstream purification of biopharmaceuticals, including those produced by fermentation of microbes, fungus or yeast, mammalian or insect cell culture and transgenic animal and plant sources.
  • the unit operations which use pH buffered solutions include filtration, centrifugation, precipitation, crystallization and chromatography.
  • Chromatography operations in particular utilize different pH buffered solutions for loading the column, washing, eluting the product, regenerating, and re-equilibrating the column. Every unit operation is achieved in discrete sub-batches or cycles, with a product batch comprised of one or more unit operation cycles.
  • Other applications for the invention might include products which themselves are pH buffered solutions. Examples of such products include ophthalmic solutions and infusion solutions.
  • the concentrated acids and bases, and in many cases other ingredients in highly concentrated forms do not themselves support microbial growth.
  • the highly concentrated acids and bases are often themselves used as the primary cleaning solutions for CIP operations, because of their ability to at least partially sanitize process systems.
  • the storage tanks and distribution systems for these ingredient feeds in the present invention do not necessarily need to be designed, constructed and operated to meet aseptic or sterile standards, and can thus be far less expensive and much simpler.
  • U.S. Pat. No. 4,907,892 entitled “Method and Apparatus for Filling, Blending, and Withdrawing Solid Particulate Material from a Vessel” discloses a method for blending solid, particulate material with liquids to form a suspension, with an apparatus with a continuous blending unit. This method, however, neither blends solutions to create aqueous buffers nor allows for the production of biopharmaceuticals.
  • the apparatus contains a sensor to monitor the quantity of material in the vessel by its height or weight plus a controller that responds to the sensor for regulating the particulate material feed rate or the material withdrawal rate in order for the material supply rate and blended substance withdrawal rate to be balanced to direct the material level inside the vessel to a preferred level.
  • a controller that responds to the sensor for regulating the particulate material feed rate or the material withdrawal rate in order for the material supply rate and blended substance withdrawal rate to be balanced to direct the material level inside the vessel to a preferred level.
  • positive displacement chemical metering pumps are utilized to proportion the ingredient streams, entering the processing plant, not to regulate or to measure the amount of solution in the blending unit.
  • the blend for each solution is regulated by the combination of the pump head sizes and adjustable stroke lengths.
  • This patent utilizes pumps for controlled flow rate and increases and decreases in the temperature of a treated solution, but does not involve blending of chemicals.
  • U.S. Pat. No. 5,552,171 entitled “Method of Beverage Blending and Carbonation” discloses a method and an apparatus to procure a very precise control of the blend, but it does not involve the blending of buffer solutions for pharmaceutical purposes.
  • the prior art (both within patents and in industry practice) teaches numerous methods of using continuous blending to produce various types of chemical solutions from mixes of solids, liquids and gases.
  • the prior art does not teach a continuous, automated blending from constitutive acids and bases of pH buffered solutions used for the production of biopharmaceuticals or other products, according to the method of the current invention.
  • the current invention provides advances in biopharmaceutical production that allow processing of compounds, especially biopharmaceutical, on a more efficient and economically flexible basis.
  • the invention can reduce the material costs for these products through the utilization of less expensive acids and bases rather than the more expensive dried salt forms of the buffering compounds.
  • the current invention is much more suitable for continuous (instead of batchwise) production methods fermentation.
  • Such production methods can be used with continuous perfusion cell culture and the production of proteins from the milk of transgenic dairy animals or from transgenic plant extracts, where the seed or plant form may provide very long term storage of the raw material, enabling continuous unit operations for purification.
  • the batchwise, manual blending of pH buffered solutions is improved upon through the use of an automated solution blending technique of the current invention.
  • This method utilizes concentrated acids and bases to form the primary buffer solution, and concentrated solutions of salts, surfactants or other additives blended in to form the final solution.
  • a small number of feed solutions is used to make a variety of reagent compositions improving efficiency of operation, decreasing error, and lowering cost.
  • the operation may be, in a preferred embodiment, continuous.
  • the buffering compounds can include inorganic acids (such as phosphoric or boric acid), simple organic acids (such as acetic or citric acids), organic bases (such as tris-hydroxymethyl amino methane (TRIS), and so-called Good's buffers including HEPES, MOPS, MES, etc.).
  • the buffering compound is usually combined with a strong base (such as sodium or potassium hydroxide), or a strong acid (such as hydrochloric) as appropriate to produce the final pH desired.
  • the acid and base are supplied to the system as liquid concentrates, usually at a very high concentration. Other ingredients are also supplied as pure liquids or concentrated solutions.
  • These other solution ingredients can include salts (such as sodium, potassium or magnesium chloride, sodium or ammonium sulfate,, and the like), surfactants (such as Tween), chaotropic or solvophobic agents (such as ethylene glycol, urea, sodium thiocyanate, or guanadinium hydrochloride), mild reducing agents (such as cysteine or mercaptoethanol), microbial or proteolytic inhibitors (such as thimerosol, sodium azide, and the like), precipitation or extraction agents (such as polyethylene glycol, dextran, and the like), etc.
  • salts such as sodium, potassium or magnesium chloride, sodium or ammonium sulfate,, and the like
  • surfactants such as Tween
  • chaotropic or solvophobic agents such as ethylene glycol, urea, sodium thiocyanate, or guanadinium hydrochloride
  • mild reducing agents such as cysteine or mercaptoethanol
  • the individual ingredients are blended.
  • the ingredients are continuously blended on demand by pumping the various streams (water, acid, base and other additives) at controlled flow rates into a mixing device (static or active mixer), and the resulting pH buffered solution is then used directly and immediately in the process.
  • Control of the pH may be implemented by placing a pH sensor downstream of the mixing point and using the value to control the relative flow rates of the acid and base streams.
  • the individual ingredients are pumped either simultaneously or sequentially into a small, stirred tank with sensors for pH, conductivity, temperature, and level.
  • a small, stirred tank with sensors for pH, conductivity, temperature, and level.
  • the solution characteristics are reviewed (either automatically or manually) against specifications. If the results are approved, the individual solution is released.
  • a second small buffer tank can be employed to permit time for blending and checking. This practice ensures that the same Good Manufacturing Practices (GMP) quality standards can be satisfied as with batchwise solution blending.
  • GMP Good Manufacturing Practices
  • FIG. 1 shows a downstream processing plant with the conventional batchwise solution blending of the prior art.
  • FIG. 2 shows a downstream plant demonstrating continuous solution blending from acids and bases.
  • FIG. 3 shows a buffer blending unit design for direct online blending.
  • FIG. 4 shows a buffer blending unit according an embodiment utilizing an inline mixing tank.
  • FIG. 5. shows a model of the facility elements of a typical of a biopharmaceutical production plant
  • FIG. 6 shows a transgenic human serum albumin process scheme.
  • FIG. 7. shows a chart comparing the cost of the current invention relative to conventional batchwise processing.
  • FIG. 8 shows human serum albumin process scheme utilizing a simulated moving bed design.
  • FIG. 9 shows an alternate and simplified transgenic human serum albumin process scheme.
  • FIG. 10 shows a downstream plant demonstrating continuous solution blending from acids and bases and SMB.
  • pH A term used to describe the hydrogen-ion activity of a chemical or compound according to well-known scientific parameters.
  • WFI An abbreviation for water for injection.
  • [0045] shall mean any medicinal drug, therapeutic, vaccine or any medically useful composition whose origin, synthesis, or manufacture involves the use of microorganisms, recombinant animals (including, without limitation, chimeric or transgenic animals), nuclear transfer, microinjection, or cell culture techniques.
  • the raw material or raw solution provided for a process or method and containing a protein of interest.
  • the method of the current invention provides an efficient process to produce pH buffered solutions that will ultimately be converted into or used as pharmaceutical products.
  • the primary ingredients that compose a mixture are water, and a buffer acid and base at a particular concentration and in a particular ratio to produce a desired final pH.
  • the solution may include other solution ingredients, such as salts, surfactants, inhibitors etc., see detailed listing above.
  • the individual ingredients are blended at the point of use using an automated blending unit.
  • reciprocating, positive displacement chemical metering pumps are used to regulate the flow of the ingredient streams.
  • the precise blend for a particular solution is fixed by the combination of pump head sizes and flexible stroke lengths.
  • the various streams are simultaneously pumped into a mixing unit of either a static or active type.
  • sensors for pH and conductivity can be placed inline after the mixer and their output utilized to control the relative ratios of the acid, base and other ingredients.
  • the solution is utilized immediately by the process being supplied.
  • the solution ingredients are metered out by pumps and mixed in a small tank.
  • the metering operation can be done simultaneously for all ingredients (using the same type of positive displacement chemical metering pumps utilized in the first embodiment).
  • the metering can be done sequentially for each ingredient, using either metering pumps or control through the use of a level sensor or load cell placed on the mixing tank.
  • the mixing tank would be equipped with sensors for pH, conductivity, level and possibly other parameters.
  • the sensor measurements would be compared to a release specification, and the solution would be released for use in the process if the specifications are met. If the solution is required to be supplied continuously to the process, two small mixing tanks could be used, one of which would supply released solution while the other is being used to blend a new tank of solution.
  • the first preferred embodiment of the invention is simpler and less expensive to construct, and may be truly continuous, according to a preferred embodiment of the invention. This would be the embodiment used for a large fraction of the applications.
  • the second embodiment incorporates some of the current elements of good manufacturing practice (GMP) for pharmaceutical manufacturing, and may be required for some particularly critical process steps.
  • GMP good manufacturing practice
  • FIG. 7 the design and testing data on the human serum albumin downstream purification process shown in FIG. 5 were used as input to a detailed process cost modeling software system (Paradigm One, Applied Process Technologies, Wilmington, Mass.). The software package estimates detailed capital and operating costs based upon specific process parameters, selected equipment, utility and space requirements, etc. For this model, a facility was designed to produce 25 tons per year of purified bulk active pharmaceutical ingredient (bulk API) from transgenic milk containing human serum albumin. For the comparison, all unit operations (see FIG. 6) were kept constant, and only the solution preparation and storage system and process utilities were modified to reflect the blending of buffers directly from acids, bases and additives.
  • a detailed process cost modeling software system Paradigm One, Applied Process Technologies, Wilmington, Mass.
  • the software package estimates detailed capital and operating costs based upon specific process parameters, selected equipment, utility and space requirements, etc.
  • bulk API purified bulk active pharmaceutical ingredient
  • 5,206,153 entitled “Method of Producing Human Alpha-Fetoprotein and Product Produced Thereby” discloses a method to make human alpha fetoprotein whereby a DNA sequence for rat alpha fetoprotein is combined with the DNA for human alpha fetoprotein. These methods, however, do not yield a supply of human alpha fetoprotein by the use of the continuous, automated blending of buffers and other solutions.
  • Serum albumin the most well-known plasma protein, is responsible for a variety of physiological functions such as sustaining the osmotic pressure in the blood and transporting fatty acids and bilirubin (Peters 1995). Testing levels of serum albumin from feedstreams may be conducted to see if the subject has liver or kidney diseases or if an insufficient amount of protein is consumed by the blood. Decreased levels of serum albumin may signal such diseases as well as ascites, bums, glomerulonephritis, malabsorption syndrome, malnutrition, and nephritic syndromes.
  • Albumin products are employed to maintain the plasma colloid oncotic pressure and to remedy severe edema by enabling intracavital and interstitial fluids to travel into the blood vessels.
  • Albumin products may be administered to alleviate acute hypoproteinemia and pathological conditions stemming from chronic hypoproteinemia.
  • Albumin products may be utilized to treat hypovolemic shock, severe bum injury, adult respiratory distress syndrome, ascites, liver failure, and pancreatitis. (Cochrane et al., 1998).
  • Albumin may also be administered to remedy hyperbilirubinemia, hypoproteinemia, and nephrotic syndrome. (Vermeulen et al., 1995).
  • Alpha fetoprotein is another protein that may be processed for beneficial reasons. It is a protein assembled by the liver and yolk sac of a fetus. Throughout pregnancy, heightened levels may signal the following fetal abnormalities: spina bifida, anencephaly, omphalocele, tetralogy of Fallot, duodenal atresia, Turner's syndrome, and intrauterine death.
  • monitoring increased levels of alpha fetoprotein may be useful in pinpointing cancers of the stomach, pancreas, biliary tract, testes, and ovaries, and recuperation from hepatitis.

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US20050273203A1 (en) * 2003-10-17 2005-12-08 Louis Bellafiore Accurate blending module and method
US7072742B1 (en) * 2003-10-17 2006-07-04 Technikrom, Inc. Accurate blending module and method
US20070085989A1 (en) * 2005-06-21 2007-04-19 Nikon Corporation Exposure apparatus and exposure method, maintenance method, and device manufacturing method
US20080053543A1 (en) * 2006-08-30 2008-03-06 Semba, Inc. Valve Module And Methods For Simulated Moving Bed Chromatography
US20080279038A1 (en) * 2003-10-17 2008-11-13 Louis Bellafiore Multi-stage accurate blending system and method
US20090156557A1 (en) * 2007-04-18 2009-06-18 Takeda San Diego, Inc. Kinase inhibitors
US7790040B2 (en) 2006-08-30 2010-09-07 Semba Biosciences, Inc. Continuous isocratic affinity chromatography
EP2585887A4 (en) * 2010-06-23 2017-05-10 GE Healthcare Bio-Sciences AB Method of preparing liquid mixtures
WO2017188917A1 (en) * 2016-04-25 2017-11-02 Safe Foods Corporation Antimicrobial application methods and systems with improved ph monitoring
US10034921B2 (en) 2013-02-13 2018-07-31 Laboratoire Français Du Fractionnement Et Des Biotechnologies Proteins with modified glycosylation and methods of production thereof
US10174110B2 (en) 2013-02-13 2019-01-08 Laboratoire Français Du Fractionnement Et Des Biotechnologies Highly galactosylated anti-TNF-α antibodies and uses thereof
US10611826B2 (en) 2013-07-05 2020-04-07 Laboratoire Français Du Fractionnement Et Des Biotechnologies Affinity chromatography matrix
EP2480305B1 (en) 2009-09-25 2020-10-28 Global Life Sciences Solutions USA LLC Separation system and method
US11553712B2 (en) 2010-12-30 2023-01-17 Laboratoire Français Du Fractionnement Et Des Biotechnologies Glycols as pathogen inactivating agents
US12247076B2 (en) 2015-07-06 2025-03-11 Laboratoire Français Du Fractionnement Et Des Biotechnologies Use of modified Fc fragments in immunotherapy

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CN107983261A (zh) * 2009-09-25 2018-05-04 通用电气健康护理生物科学股份公司 用于液体混合物的制备的方法和系统
WO2012076441A1 (en) 2010-12-07 2012-06-14 F. Hoffmann-La Roche Ag Feed mixing device and its use
WO2015104794A1 (ja) * 2014-01-08 2015-07-16 株式会社日立製作所 試料前処理装置

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